AC lines are resolved. Finally. Just need to get two ferrules/crimps- one on each. Compressor high side line is an original 04/05 high side, cut on the end with an NA high side barb fitting inserted. The other is the 04/05 low side fitting cut right after the 90° with a barb brazed on the end.
But that's not where it started. The first solution was using two other fittings cut at the compressor with barbs brazed on to make the 04/05-compressor-to-NA system conversion. It made for a very clean routing.
I brazed the joints using Alumiweld picked up from Harbor Freight. I've used this stuff before- though not for sealing, just attaching. Worked as before- fairly straight forward if you get good heat into the base metal. I ended up sleeving the high side (smaller diameter) since I couldn't get it to expand enough to make a joint w/o splitting. In the end I produced what looked to be a good brazed joint on both line fittings.
BUT when I pressure test both joints they produced bubbles in soapy water around the entire joint. And once this stuff is laid down, there's no removing it like an electrical solder joint.
Back to square one- with enough fittings to finish the job, but not enough to make mistakes. Enter Alcor brazing alloy. This is what hvac techs use. $15-20 for 3ft - but you don't use much. This
time I made a test joint (learn from my mistakes) with like
tubing and pressure tested first. Used the same technique as aluminweld focusing the heat on the base metal. Got a sealed joint on the first try.
On to the actual job. Started by removing the barbs I need from existing AC lines (glad I salvaged these from way back). Cut the ferrules on both sides.
Pry apart until it splits and can be removed.
Then annealed and swaged the barb end that was pulled from the hose so it can accept the compressor fitting tube with enough tolerance for molten brazing alloy.
The Alcor flowed in much like sweating a copper pipe. Propane works well since it's capable of the 824°f temp needed for the brazing alloy. Produce a pressure-tested quality brazed joint on the first try.
Final routing with plenty of clearance for both lines.
Lines ready for crimps. Once that's done and connections are made, the system will be ready to charge.
For the record- here's what 25 year old AC hoses typically look like.